2004 Transfer Case Replacement Help

Slaughterrt

Slaughterrt

Member
Joined
Apr 29, 2020
Messages
37
Location
Forked River, NJ
2004 JEEP WRANGLER SPORT 4X4 SPORT UTILITY 2-DR
5 SPD MANUAL
DANA 44 REAR AXLE

So I am replacing my wrecked 231J transfer case with a pre-owned one. I have been doing some research and whatnot about the parts, but I wanted to get some opinions before taking the plunge and buying. Having a hard time figuring out if my make/model/year has a 231J with a short input or long input shaft…or if that even matters. The seller claims that 231J short input shaft will fit all standard 97-06. It also fits 03-06 automatics (doesn’t affect me). They also claim some standard 97-04 used the long input shaft.

Honestly just need to know which version to purchase (or if the short input is interchangeable).

Figuring out which I need will help determine which rear drive shaft I need to purchase, as well as which rear yoke.

Thanks all

Rob
 
For the yoke, it will depend on if the new t-case has an SYE kit on it (and I guess if your old t-case also had one). But you probably won't need a new yoke.
  • If you had one, and the new one doesn't, just transfer the SYE to the new case & use your old rear driveshaft as-is.
  • if you had one and the new one also does, your double-cardan driveshaft will bolt right up to the yoke on the output.
  • If you didn't have one and the new one also doesn't, your driveshaft will just spline onto the t-case output shaft.
  • If you didn't have one and the new one does...
    • either get a new double cardan driveshaft to bolt up to the yoke on the new t-case
    • OR remove the SYE & scavenge the output section from your old t-case and re-use your old driveshaft.
I guess we probably need to know what is broke'd on your case. The new one will either have a long splined output shaft (i.e. no SYE) or a yoke (i.e. has an SYE). I don't know which years/transmissions used which length input shaft but I believe they are interchangeable. Blaine will know for sure, probably others as well.
 
hear said:
For the yoke, it will depend on if the new t-case has an SYE kit on it (and I guess if your old t-case also had one). But you probably won't need a new yoke.
  • If you had one, and the new one doesn't, just transfer the SYE to the new case & use your old rear driveshaft as-is.
  • if you had one and the new one also does, your double-cardan driveshaft will bolt right up to the yoke on the output.
  • If you didn't have one and the new one also doesn't, your driveshaft will just spline onto the t-case output shaft.
  • If you didn't have one and the new one does...
    • either get a new double cardan driveshaft to bolt up to the yoke on the new t-case
    • OR remove the SYE & scavenge the output section from your old t-case and re-use your old driveshaft.
I guess we probably need to know what is broke'd on your case. The new one will either have a long splined output shaft (i.e. no SYE) or a yoke (i.e. has an SYE). I don't know which years/transmissions used which length input shaft but I believe they are interchangeable. Blaine will know for sure, probably others as well.
Click to expand...

Sorry for the slow reply, busy day yesterday.

So what started this was when the Jeep crapped out on the highway. Ended up shearing off the output shaft on the transfer case, completely losing the rear drive shaft, and busting the u-joint at the yoke. After research I decided to just get a “lesser miles” transfer case and just replace the t-case, the driveshaft, and the yoke. All of my parts were stock, and I’m looking to replace with stock. The tricky part is just that there are several options of “stock”, so it’s harder to determine which parts I need. Thanks for the help.
 
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I still have my original output shaft from my 231J. Left over from putting in a SYE.

Welcome to it if you want to pay shipping.

Bet you'd find a bunch locally to if you put a shout out to the local Jeep clubs on FB.

Personally I'd just order a SYE kit and a rear driveshaft. I got mine from Adam's Driveshaft. Tom Woods is also a good source.

-Mac
 
macleanflood said:
I still have my original output shaft from my 231J. Left over from putting in a SYE.

Welcome to it if you want to pay shipping.

Bet you'd find a bunch locally to if you put a shout out to the local Jeep clubs on FB.

Personally I'd just order a SYE kit and a rear driveshaft. I got mine from Adam's Driveshaft. Tom Woods is also a good source.

-Mac
Click to expand...

Is it worth it to install a SYS kit? Honestly don’t offroad the TJ very often.
 
Slaughterrt said:
Is it worth it to install a SYS kit? Honestly don’t offroad the TJ very often.
Click to expand...

You would keep your 231J. That's a huge bonus...you don't know how thrashed a use box is...until you open it up.

You'd be spending money towards better parts rather than sideways.

You'd end up with a new driveshaft which would address any damage done to your existing shaft or u joints.

Just my train of thought.

Obviously if you can source a new main shaft...and lots of us have them...then go that route.

-Mac
 
macleanflood said:
I still have my original output shaft from my 231J. Left over from putting in a SYE.

Welcome to it if you want to pay shipping.

Bet you'd find a bunch locally to if you put a shout out to the local Jeep clubs on FB.

Personally I'd just order a SYE kit and a rear driveshaft. I got mine from Adam's Driveshaft. Tom Woods is also a good source.

-Mac
Click to expand...

What I gather is OP was driving down the road and something detonated causing broken output shaft and blown up universal? Should he determine the cause before ordering a sye and new shaft? Asking for the OP
 
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macleanflood said:
You would keep your 231J. That's a huge bonus...you don't know how thrashed a use box is...until you open it up.

You'd be spending money towards better parts rather than sideways.

You'd end up with a new driveshaft which would address any damage done to your existing shaft or u joints.

Just my train of thought.

Obviously if you can source a new main shaft...and lots of us have them...then go that route.

-Mac
Click to expand...

I do like the idea of not playing roulette with a used transfer case.
 
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Weasellee said:
What I gather is OP was driving down the road and something detonated causing broken output shaft and blown up universal? Should he determine the cause before ordering a sye and new shaft? Asking for the OP
Click to expand...

Bingo. A while back I started feeling some vibration while driving. I misdiagnosed it as a bad o2 sensor because I threw a CEL for a o2 sensor and misfire around the same time. I kid you not, the day after I change the o2 sensor, my rear driveshaft decides to liberate itself from the transfer case. Looking at the damage, and what was left of the transfer case and ujoint, my best guess is that the ujoint between the rear drive shaft to the rear diff failed (and the failing ujoint would explain the vibration I had been feeling). Looks like when the ujoint failed, the rear driveshaft spun around and snapped the rear output shaft from the transfer case.
So ultimately, I need to replace that rear output shaft coming from the transfer case (whether that’s going the “new used” transfer case route or by getting a new output shaft or by doing a SYE), plus a new rear driveshaft, plus a new ujoint yoke probably.
Just trying to figure out the most cost effective way of doing this.
Thanks all.
 
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Is there a "witness mark" from where the driveshaft slammed into the underside of the tub after it broke free from the diff?
 
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